DBS Transform Reduces Time to Reverse Engineer Gearboxes

Gearboxes are engineered to endure challenging environments and operate for extended lifespans. However, over time, circumstances can change, prompting end users to seek support from providers other than the original manufacturer. This need arises due to various reasons, such as the original manufacturer going out of business or persistent performance issues with the gearbox.

Traditionally, while end users could engage third-party service providers, they often remained dependent on the original manufacturer for spare parts and units. Conventional reverse engineering techniques for gears were time-consuming, often requiring weeks of work and necessitating the shipment of gears to a manufacturing site for precise measurement.

Given that gearboxes are critical components operating around the clock, the lengthy reverse engineering process posed significant challenges for end users seeking alternative spare part supply options.

Introducing DBS Transform

Enter DBS Transform from David Brown Santasalo - an innovative solution born from the synergy of cutting-edge structured light 3D scanners and nearly three centuries of combined gearing expertise. These 3D scanners significantly reduce the time required to reverse engineer a gearbox. In many instances, the necessary data to design a new complete drivetrain can be captured within a scheduled shutdown window of less 10 hours.

Once the 3D scanning is completed, the gearbox can resume operation while a new drivetrain is designed and manufactured at one of DBS's state-of-the-art gear manufacturing facilities. When the parts are ready, the transformation can be finalized at any of the numerous DBS service centers worldwide or even on the customer's site.

During this process, the gearcase undergoes a thorough inspection and refurbishment as needed. The end result is effectively a new gearbox with a recycled gearcase, ensuring peace of mind for the customer as the gearbox mounting interface remains identical to its original state.

With DBS Transform, end users are no longer bound to the original gearbox manufacturer, gaining the freedom to choose their aftermarket support and spare parts provider. DBS Transform empowers end users to fully transition their gearbox aftermarket support to DBS, who offer proactive support throughout the entire lifecycle of the asset. Additionally, DBS Transform is more cost-effective than purchasing a new spare unit, offers quicker turnaround times, lower installation risks, and comes with a new gearbox warranty.

“It's incredibly exciting to leverage cutting-edge technology, alongside our world-leading gearbox expertise to tackle long-standing industry challenges. DBS has reverse-engineered gearboxes for decades, but now, with significantly reduced data capture times, we can transform any make and model of gearbox without causing unplanned downtime for our customers. The result of this is that the end user has the assurance of a new gearbox warranty and a comprehensive one-stop shop for all their aftermarket needs,” said Joel Sics, professional services product line director at David Brown Santasalo.